JP7459081B2 - Elastomeric polyurethane foam and its production method - Google Patents

Description

This application relates generally to elastomeric polyurethane foams having improved high temperature performance and methods for producing such elastomeric polyurethane foams.

Elastomeric polyurethane foams are commonly used in the manufacture of many materials needed for high temperature applications, such as air filter gaskets, filter seals, filter end caps, and engine covers used in internal combustion engines. The trend to improve automobile engine performance has led to higher temperatures within the engine compartment. This increase in temperature has created a need for materials that are more resistant to prolonged exposure to elevated temperatures.

Therefore, there is a need for elastomeric polyurethane foams with improved high temperature performance, and such foams can be manufactured using existing manufacturing processes and readily available raw materials.

Embodiments of the present disclosure include elastomeric polyurethane foams with improved high temperature performance, including, but not limited to, (a) monomeric diphenylmethane diisocyanate (MMDI) and polymeric MDI (PMDI); an isocyanate-functional urethane prepolymer derived from one or more prepolymers comprising an ether diol; and (b) an isocyanate-reactive component, wherein (i) an amount of from about 10 to about 70 parts by weight of the isocyanate-reactive component. (ii) a first polyol, wherein the first polyol is a nominal propylene oxide or ethylene oxide capped diol having a number average molecular weight of about 1000 g/mol to about 9000 g/mol; a randomly dispersed high proportion of a second polyol in an amount of about 0 to about 50 parts by weight of the isocyanate-reactive component, the second polyol having a number average molecular weight of about 1000 g/mol to about 8000 g/mol; (iii) a third polyol in an amount of from about 0 to about 20 parts by weight of the isocyanate-reactive component, the third polyol comprising a nominal triol having ethoxy groups of a third polyol comprising a nominal ethylene oxide-capped tetraol having a number average molecular weight of from mole to about 6000 g/mole, and (iv) a fourth in an amount of from about 0 to about 80 parts by weight of the isocyanate-reactive component. an isocyanate-reactive polyol, wherein the fourth polyol is a nominal triol capped with ethylene oxide or propylene oxide having a number average molecular weight of about 1000 g/mol to about 13000 g/mol; and an isocyanate-reactive component, wherein at least one of components (ii), (iii), and (iv) is present in greater than about 0 parts by weight.

In one embodiment, the first polyol includes from about 30 to about 70 parts by weight of an isocyanate-reactive component. In another embodiment, the first polyol includes about 35 to about 65 parts by weight of an isocyanate-reactive component. In certain embodiments, the first polyol has a number average molecular weight of about 6000 g/mole and a functionality of 1.5 to 2.0.

In one embodiment, the second polyol includes from about 0 to about 45 parts by weight of an isocyanate-reactive component. In another embodiment, the second polyol includes from about 15 to about 40 parts by weight of an isocyanate-reactive component. In certain embodiments, the second polyol has a number average molecular weight of about 3600 g/mole and a functionality of 2.8 to 3.0.

In one embodiment, the third polyol comprises about 0 to about 15 parts by weight of the isocyanate-reactive component. In another embodiment, the third polyol comprises about 0 to about 10 parts by weight of the isocyanate-reactive component. In a particular embodiment, the third polyol has a number average molecular weight of about 5250 g/mole and a functionality of 3.5 to 5.0.

In one embodiment, the fourth polyol includes from about 0 to about 30 parts by weight of an isocyanate-reactive component. In another embodiment, the fourth polyol includes from about 0 to about 15 parts by weight of an isocyanate-reactive component. In certain embodiments, the fourth polyol has a number average molecular weight of about 2800-6000 g/mole and a functionality of 2.1-3.0.

In one embodiment, the isocyanate-reactive component further comprises an additive package in an amount of about 1 to about 30 parts by weight of the isocyanate-reactive component. The additive package includes blowing agents, catalysts, colorants, dyes, pigments, crosslinkers, flame retardants, diluents, solvents, inorganic fillers, surfactants, inorganic fillers, antioxidants, UV stabilizers, and biocides. The composition includes ingredients selected from those classified by those skilled in the art as agents, adhesion promoters, antistatic agents, mold release agents, fragrances, and any combinations thereof. The blowing agent can be a chemical blowing agent in an amount from about 0.1 to about 4 parts by weight of the isocyanate-reactive component. The blowing agent can also be a physical blowing agent in an amount of about 0 to 12 parts by weight of the isocyanate-reactive component. The chemical blowing agent can be, but is not limited to, water. The physical blowing agent can be, but is not limited to, HCFO-1233zd(E).

In another embodiment, the isocyanate-reactive component may include a surfactant in an amount of about 0 to about 6, or even about 5 parts by weight of the isocyanate-reactive component. In certain embodiments, the surfactant can be Dabco® DC5000, or a chemically equivalent alternative available under different trade names. In additional embodiments, the isocyanate-reactive component may include a chain extender in an amount from about 0 to about 10 parts by weight of the isocyanate-reactive component. In certain embodiments, the chain extender can be 1,4-butanediol (BDO).

In one embodiment, the MMDI used to form the isocyanate-functional urethane prepolymer is in an amount of about 20 to about 70 parts, and the MMDI is at least 97% by weight 4,4'-MDI. In another embodiment, the PMDI used to form the isocyanate-functional urethane prepolymer is in an amount of about 20 to about 70 parts, and the PMDI has a viscosity of about 150 to about 850 cps at 25°C and a ~ has a percent NCO of about 32.5. In yet another embodiment, the polyether diol used to form the isocyanate-functional urethane prepolymer is in an amount from about 5 to about 30 parts, and the polyether diol is from about 425 g/mol to about 6000 g/mol. It has a number average molecular weight of molar and a functionality of 1.2 to 2.0. In further embodiments, the polyether diol has a number average molecular weight of about 425 g/mol and a functionality of 1.75 to 2.0, or a number average molecular weight of about 6000 g/mol and a functionality of 1.5 to 2.0. has. In certain embodiments, the MMDI is Lupranate M, the PMDI is Lupranate M20, and the polyether diol is Pluracol 410 or Pluracol 1062. .

In one embodiment, multiple prepolymers can be used to produce an isocyanate-functional urethane prepolymer. In some embodiments, for example, the first prepolymer can include MMDI and the second prepolymer can include a polyether prepolymer. The ratio of prepolymers can be varied depending on the desired properties of the final product, ie the improved elastomeric polyurethane foam of the present invention. In certain embodiments, the ratio of the first prepolymer to the second prepolymer used to produce the isocyanate-functional urethane prepolymer is from 99:1 to 50:50, or from 99:1 to It may include a ratio (by weight) of 70:30, 80:30, or 90:10. In some embodiments, these ratios may vary from 80:20 to 60:40, or from 75:25 to 65:35, or from 70:30. In some embodiments, the first prepolymer is present in an amount of 50% or more compared to the second prepolymer.

In one embodiment, the constant deflection compression set values at 40% deflection for the elastomeric polyurethane foams of the present disclosure according to ASTM D3574 are: Less than about 40%. In another embodiment, the constant deflection compression set values at about 30% to about 50% deflection of the elastomeric polyurethane foams of the present disclosure according to ASTM D3574 range from about 22 to about 100% at about 100° C. to about 130° C. When compressed in time, it is less than about 40%.

In one embodiment, the tensile strength value of the elastomeric polyurethane foam of the present disclosure according to ASTM D3574 is from about 50 pounds per square inch to about 285 pounds per square inch. In another embodiment, the tear strength values for the elastomeric polyurethane foams of the present disclosure according to ASTM D3574 are from about 13 pounds per inch to about 40 pounds per inch. In yet another embodiment, the elongation at break value of the elastomeric polyurethane foam of the present disclosure according to ASTM D3574 is about 50% to about 160%. However, hereinafter, 1 pound = 0.4536 kg, 1 inch = 25.4 mm, 1 foot = 0.3048 m, and 1 psi = 6894.76 Pa.

In one embodiment, the tensile strength values of the elastomeric polyurethane foams of the present disclosure according to ASTM D3574 undergo a change of less than about 50% when the foams are aged at about 102° C. for about 70 hours. In another embodiment, the tear strength values of the elastomeric polyurethane foams of the present disclosure according to ASTM D3574 change by less than about 30% when the foams are aged at about 102° C. for about 70 hours. In yet another embodiment, the elongation at break value of the elastomeric polyurethane foam of the present disclosure according to ASTM D3574 changes by less than about 50% when the foam is aged at about 102° C. for about 70 hours.

In one embodiment, the tensile strength values of the elastomeric polyurethane foams of the present disclosure according to ASTM D3574 undergo a change of less than about 35% when the foams are aged at about 60° C. and about 95% relative humidity for about 168 hours. In another embodiment, the tear strength values of the elastomeric polyurethane foams of the present disclosure according to ASTM D3574 undergo a change of less than about 35% when the foams are aged at about 60° C. and about 95% relative humidity for about 168 hours. In yet another embodiment, the elongation at break value of the elastomeric polyurethane foam of the present disclosure according to ASTM D3574 changes by less than about 35% when the foam is aged at about 60° C. and about 95% relative humidity for about 168 hours. receive.

Also disclosed is a method of forming an elastomeric polyurethane foam, the method comprising reacting MMDI and PMDI with a polyether diol to form an isocyanate-functional urethane prepolymer; blending a polyol, a third polyol, and a fourth polyol to form an isocyanate-reactive component; and mixing an isocyanate prepolymer and an isocyanate-reactive component at an isocyanate index of about 100 to about 110. forming an elastomeric polyurethane foam, the first polyol having a number average molecular weight of about 1000 g/mol to about 9000 g/mol, comprising about 10 to about 70 parts by weight of an isocyanate-reactive component. or an ethylene oxide-capped nominal diol, wherein the second polyol has a high proportion of randomly distributed ethoxy groups having a number average molecular weight of about 1000 g/mol to about 8000 g/mol; parts by weight of an isocyanate-reactive component, and the third polyol is a nominal tetraol capped with ethylene oxide having a number average molecular weight of about 250 g/mol to about 6000 g/mol, about 0 to about 15 parts by weight of an isocyanate-reactive component, and the fourth polyol is a nominal triol capped with ethylene oxide or propylene oxide having a number average molecular weight of about 1000 g/mol to about 13000 g/mol, and about 0 to about 80 g/mol. Contains parts by weight of isocyanate-reactive components.

Other features and advantages may become apparent from the detailed description below.

The elastomeric polyurethane foams of the present disclosure include the reaction product of an isocyanate component and an isocyanate-reactive component. It is to be understood that as used herein, the term "isocyanate component" is not limited to monomeric diphenylmethane diisocyanate (MMDI), i.e., the isocyanate component may include MMDI and polymeric polyisocyanate (PMDI). . Additionally, as used herein, the term "isocyanate component" encompasses isocyanate-terminated quasi-prepolymers, or those materials commonly referred to as prepolymers. In certain embodiments, a prepolymer, such as a polyol reacted with excess isocyanate, may be utilized as the isocyanate component in this disclosure. Isocyanate components include, but are not limited to, 4,4'-MDI, 2,4'-MDI, PMDI, prepolymers (built from 4,4'-MDI, PMDI, 2,4'-MDI) , carbodiimide modified isocyanates, biuret modified isocyanates, allophanate modified isocyanates, and combinations thereof. In one embodiment, the isocyanate component includes an n-functional isocyanate, where "n" can be a number from 2 to 5, 2 to 4, or 3 to 4. It should be understood that "n" can be an integer or have intermediate values from 2 to 5. The isocyanate component may also include isocyanates selected from the group of aromatic isocyanates, aliphatic isocyanates, and combinations thereof. In another embodiment, the isocyanate component includes aliphatic isocyanates such as hexamethylene diisocyanate, H12MDI, and combinations thereof. When the isocyanate component includes an aliphatic isocyanate, the isocyanate component may also include modified polyvalent aliphatic isocyanates, i.e., products obtained through the chemical reaction of aliphatic diisocyanates and/or aliphatic polyisocyanates. Examples include, but are not limited to, ureas, biurets, allophanates, carbodiimides, uretonimines, isocyanurates, urethane groups, dimers, trimers, and combinations thereof. Isocyanate components may also include, but are not limited to, individually or polyoxyalkylene glycols, diethylene glycol, dipropylene glycol, polyoxyethylene glycol, polyoxypropylene glycol, polyoxypropylene polyoxethylene glycols, polyesterols. , polycaprolactone, and combinations thereof.

Alternatively, the isocyanate component may include aromatic isocyanates. When the isocyanate component includes an aromatic isocyanate, the aromatic isocyanate may correspond to the formula R'(NCO) _z , where R' is aromatic and z corresponds to the valence of R'. is an integer. Preferably z is at least 2. Suitable examples of aromatic isocyanates include, but are not limited to, tetramethylxylylene diisocyanate (TMXDI), 1,4-diisocyanatobenzene, 1,3-diisocyanato-o-xylene, 1,3-diisocyanato- p-xylene, 1,3-diisocyanato-m-xylene, 2,4-diisocyanato-1-chlorobenzene, 2,4-diisocyanato-1-nitrobenzene, 2,5-diisocyanato-1-nitrobenzene, m-phenylene diisocyanate, p -phenylene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, mixture of 2,4-toluene diisocyanate and 2,6-toluene diisocyanate, 1,5-naphthalene diisocyanate, 1-methoxy-2,4- Phenyl diisocyanate, 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, 4,4'-biphenylene diisocyanate, 3,3'-dimethyl-4,4'-diphenylmethane diisocyanate, 3,3'-dimethyldiphenylmethane- Triisocyanates such as 4,4'-diisocyanate, 4,4',4''-triphenylmethane triisocyanate, polymethylene polyphenylene polyisocyanate and 2,4,6-toluentirisocyanate, 4,4'-dimethyl-2,2 Tetraisocyanates such as '-5,5'-diphenylmethane tetraisocyanate, toluene diisocyanate, 2,2'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, 4,4'-diphenylmethane diisocyanate, polymethylene polyphenylene polyisocyanate, etc. Corresponding isomer mixtures as well as combinations thereof are mentioned.Alternatively, aromatic isocyanates include the triisocyanate product of m-TMXDI and 1,1,1-trimethylolpropane, toluene diisocyanate and 1,1,1 - reaction products with trimethylolpropane, and combinations thereof. In one embodiment, the isocyanate component is selected from the group of methylene diphenyl diisocyanate, toluene diisocyanate, hexamethylene diisocyanate, H12MDI, and combinations thereof. Contains diisocyanates.

The isocyanate component used to prepare the prepolymer can have any percent NCO content and any viscosity. Some non-limiting percent NCO values are about 1 to about 60, about 5 to about 50, about 10 to about 40, about 20 to about 35, about 30 to about 60, about 1 to about 32.5, or about 30 to about 32.5. Isocyanate components used to prepare the prepolymer may include MMDI, PMDI, and combinations thereof. Some non-limiting viscosity values for the isocyanate at 25° C. are about 0 to about 8000 cps, about 0 to about 5000 cps, about 50 to about 4000 cps, about 100 to about 3000 cps, about 120 to about 1500 cps, about 150 to about about 5000 cps, about 0 to about 850 cps, or about 150 to about 850 cps. The isocyanate component may also be reacted with the polyol and/or chain extender in any amount as determined by one skilled in the art. In certain embodiments, the isocyanate used in this disclosure may have the trade names Lupranate® M and/or Lupranate® M20.

The prepolymer is then used to prepare a urethane foam, and the prepolymer can have any percent NCO content and any viscosity. The prepolymer component may also be reacted with the resin and/or chain extender in any amount as determined by one skilled in the art. Preferably, the isocyanate component and the resin and/or chain extender react with an isocyanate index of about 95 to about 130, or about 100 to about 115. The isocyanate index is the actual molar amount of isocyanate(s) reacted with the polyol(s) and the stoichiometry of the isocyanate(s) required to react with an equivalent molar amount of polyol(s). It is the ratio to the target molar amount. In one embodiment, commercially available isocyanates can be used.

In one embodiment, multiple prepolymers can be used to produce an isocyanate-functional urethane prepolymer. In some embodiments, for example, the first prepolymer can include MMDI and the second prepolymer can include a polyether prepolymer. In another example, isocyanate-functional urethane prepolymers can include polyether prepolymers such as PMDI/MMDI-P410 prepolymers (eg, Elastofoam 24050T) and MMDI-P410/DEG prepolymers (eg, Elastofoam MP102). The ratio of prepolymers may vary depending on the desired properties of the final product, namely the heat resistance of the improved elastomeric polyurethane foams of the present invention. In certain embodiments, the ratio of the first prepolymer to the second prepolymer used to produce the isocyanate-functional urethane prepolymer is from 99:1 to 50:50, or from 99:1 to It may include a ratio (by weight) of 70:30, 80:30, or 90:10. In some embodiments, these ratios may vary from 80:20 to 60:40, or from 75:25 to 65:35, or from 70:30. In some embodiments, the first prepolymer is present in an amount of 50% or more compared to the second prepolymer.

The isocyanate-reactive components of the present disclosure may include one or more of polyether polyols, polyester polyols, and combinations thereof. As is known in the art, polyether polyols are typically formed from the reaction of an initiator with an alkylene oxide. Preferably, the initiator is selected from the group of aliphatic initiators, aromatic initiators, and combinations thereof. In one embodiment, the initiator is ethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, trimethylene glycol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, 1,2 -Pentanediol, 1,4-pentanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, butenediol, butynediol, xylylene glycol, amylene glycol, 1,4- Phenylene-bis-β-hydroxyethyl ether, 1,3-phenylene-bis-β-hydroxyethyl ether, bis-(hydroxy-methyl-cyclohexane), thiodiglycol, glycerol, 1,1,1-trimethylolpropane, 1,1,1-trimethylolethane, 1,2,6-hexanetriol, α-methylglucoside, pentaerythritol, sorbitol, aniline, o-chloroaniline, p-aminoaniline, 1,5-diaminonaphthalene, methylenedi Aniline, condensation products of aniline and formaldehyde, 2,3-, 2,6-, 3,4-, 2,5-, and 2,4-diaminotoluene and isomer mixtures, methylamine, triisopropanolamine, Ethylenediamine, 1,3-diaminopropane, 1,3-diaminobutane, 1,4-diaminobutane, propylenediamine, butylenediamine, hexamethylenediamine, cyclohexalediamine, phenylenediamine, tolylenediamine, xylylenediamine, 3, alkanolamines, including 3'-dichlorobenzidine, 3,3'- and dinitrobenzidine, ethanolamine, aminopropyl alcohol, 2,2-dimethylpropanolamine, 3-aminocyclohexyl alcohol, and p-aminobenzyl alcohol; selected from a group of combinations. It is contemplated that any suitable initiator known in the art can be used in this disclosure.

Preferably, the alkylene oxide that reacts with the initiator to form the polyether polyol is ethylene oxide, propylene oxide, butylene oxide, amylene oxide, tetrahydrofuran, alkylene oxide-tetrahydrofuran mixtures, epihalohydrin, aralkylene oxide, and combinations thereof. selected from the group. More preferably, the alkylene oxide is selected from the group of ethylene oxide, propylene oxide, and combinations thereof. Most preferably the alkylene oxide comprises ethylene oxide. However, it is also contemplated that any suitable alkylene oxide known in the art can be used in this disclosure.

The polyether polyol may include about 3 to about 25 weight percent ethylene oxide caps, based on the total weight of the polyether polyol. Without intending to be bound by any particular theory, it is believed that the ethylene oxide caps promote an increased rate of reaction of the polyether polyol with the isocyanate. In some embodiments, the ethylene oxide is randomly distributed throughout the polymer chains of the polyol in a proportion of about 1 to about 90, or even about 3 to about 75 mole percent ethylene oxide.

The polyether polyol may contain from about 3 to about 25 weight percent propylene oxide cap, based on the total weight of the polyether polyol. In other embodiments, the polyether polyol may be comprised solely of propylene oxide as the alkoxylating agent. Without intending to be bound by any particular theory, it is believed that the propylene oxide cap reduces the rate of reaction between the polyether polyol and the isocyanate. In some embodiments, the propylene oxide capped polyol contains ethylene oxide randomly distributed in the polymer chains of the polyol in a proportion of about 2 to 25, or even about 2 to 15 mole percent ethylene oxide.

Polyether polyols may also have a number average molecular weight of 18 to 10,000 g/mol. Furthermore, the polyether polyol may have a hydroxyl number of 15-6, 250 mg KOH/g. Polyether polyols may also have a nominal functionality of 2 to 8. Furthermore, the polyether polyol may also contain organic functional groups selected from the group of carboxyl groups, amine groups, carbamate groups, amide groups, and epoxy groups.

Referring now to the polyester polyols introduced above, polyester polyols are polycaprolactone esters or can be produced from the reaction of dicarboxylic acids and glycols having at least one primary hydroxyl group. Suitable dicarboxylic acids include, but are not limited to, adipic acid, methyladipic acid, succinic acid, suberic acid, sebacic acid, oxalic acid, glutaric acid, pimelic acid, azelaic acid, phthalic acid, terephthalic acid, isophthalic acid, and may be selected from the group of combinations thereof. Suitable glycols include, but are not limited to, those described above.

The polyester polyol may also have a number average molecular weight of 80 to 1500 g/mol. Additionally, the polyester polyol may have a hydroxyl value of 40 to 600 mg KOH/g. The polyester polyol may also have a nominal functionality of 2 to 8. Additionally, the polyester polyol may also include organic functional groups selected from the group of carboxyl groups, amine groups, carbamate groups, amide groups, and epoxy groups.

The first polyol can have a number average molecular weight of about 6000 g/mol and a functionality of 1.5 to 2.0. One non-limiting representative example of a first polyol used in the isocyanate-reactive component in this disclosure is Pluracol® 1062 polyol, which has a polyol of about 1000 g/mol to about 9000 g/mol. is a nominal ethylene oxide-capped diol with a number average molecular weight of . Some non-limiting effective amounts of Pluracol® 1062 include from about 1 to about 99 parts by weight, from about 5 to about 90 parts, from about 10 to about 80 parts, from about 10 to about 10 parts by weight of the isocyanate-reactive component. about 70 parts by weight, about 20 to about 75 parts by weight, about 30 to about 70 parts by weight, about 35 to about 65 parts by weight, about 35 to about 99 parts by weight, and about 1 to about 65 parts by weight.

The second polyol can have a number average molecular weight of about 3600 g/mole and a functionality of 2.8 to 3.0. One non-limiting representative example of a second polyol is Pluracol® 593 polyol, which is a randomly dispersed polymer having a number average molecular weight of about 1000 g/mol to about 8000 g/mol. It is a nominal triol with a proportion of ethoxy groups. Some non-limiting effective amounts of Pluracol® 593 include about 0 to about 99 parts by weight, about 0 to about 90 parts by weight, about 0 to about 80 parts by weight, about 0 to about 90 parts by weight of the isocyanate-reactive component. about 70 parts by weight, about 0 to about 50 parts by weight, about 0 to about 45 parts by weight, about 15 to about 40 parts by weight, about 15 to about 99 parts by weight, and about 0 to about 40 parts by weight.

The third polyol can have a number average molecular weight of about 5250 g/mole and a functionality of 3.5 to 5.0. One non-limiting representative example of a third polyol is Lupranol® 2010/1, which is capped with ethylene oxide and has a number average molecular weight of about 250 g/mol to about 6000 g/mol. It is a nominal tetraol. Some non-limiting effective amounts of Lupranol® 2010/1 include about 0 to about 99 parts by weight, about 0 to about 90 parts by weight, about 0 to about 80 parts by weight, about 0 to about 70 parts by weight, about 0 to about 50 parts by weight, about 0 to about 20 parts by weight, about 0 to about 15 parts by weight, and about 0 to about 10 parts by weight.

The fourth polyol can have a number average molecular weight of about 2800-6000 g/mol and a functionality of 2.1-3.0. One non-limiting representative example of a fourth polyol is Pluracol® 2097 polyol, which is capped with ethylene oxide and has a number average molecular weight of about 1000 g/mol to about 13000 g/mol. Nominally triol. Some non-limiting effective amounts of Pluracol® 2097 polyol include about 0 to about 99 parts by weight, about 0 to about 90 parts by weight, about 0 to about 80 parts by weight, about 0 parts by weight of the isocyanate-reactive component. to about 70 parts by weight, about 0 to about 50 parts by weight, about 0 to about 30 parts by weight, about 0 to about 15 parts by weight, about 0 to about 10 parts by weight, and about 0 to about 5 parts by weight.

Another non-limiting representative example of a fourth polyol is Pluracol® 4156 polyol, which is capped with propylene oxide and has a number average molecular weight of about 1000 g/mol to about 13000 g/mol. It is a nominal triol. Some non-limiting effective amounts of Pluracol® 4156 polyol include about 0 to about 99 parts by weight, about 0 to about 90 parts by weight, about 0 to about 80 parts by weight, about 0 parts by weight of the isocyanate-reactive component. to about 70 parts by weight, about 0 to about 50 parts by weight, about 0 to about 30 parts by weight, about 0 to about 15 parts by weight, about 0 to about 10 parts by weight, and about 0 to about 5 parts by weight.

The elastomeric polyurethane foams of this disclosure may also contain an additive ingredient package. In certain embodiments, additive components can be used in the isocyanate-reactive component. Additive components include, but are not limited to, surfactants, catalyst blocking agents, blowing agents, colorants, dyes, pigments, crosslinkers, flame retardants, diluents, solvents, inorganic fillers, catalysts, antioxidants, etc. special functional agents, UV stabilizers, biocides, adhesion promoters, antistatic agents, mold release agents, fragrances, and combinations of these groups. When utilized, the additive component is capable of isocyanate-reactive in an amount of greater than 1 to about 30, more typically about 1 to about 20 parts by weight, based on 100 parts of total polyol present in the isocyanate-reactive component. can be present in sexual components.

Flame retardant additives can be used to produce elastomeric polyurethane foams that exhibit flame retardant properties. For example, minerals such as aluminum trihydrate; salts such as hydroxymethyl phosponium salts; phosphorus compounds; phosphoric esters; and halocarbons or other compounds such as those containing bromine and/or chlorine. Flame retardant additives, including halogenated compounds, may be included in the isocyanate-reactive component.

Crosslinkers with nominal functionality ranging from 3 to 6 can be used to produce the elastomeric polyurethane foams of this disclosure. In one embodiment, a crosslinking agent can be used in the isocyanate-reactive component. Crosslinking agents generally can enable phase separation between copolymer segments of elastomeric polyurethane foams. That is, elastomeric polyurethane foams typically include both rigid urea copolymer segments and flexible polyol copolymer segments. Crosslinkers typically chemically and physically link the hard urea copolymer segments to the soft polyol copolymer segments. Therefore, crosslinking agents are typically present in the isocyanate-reactive component to modify hardness, increase stability, and reduce shrinkage of elastomeric polyurethane foams. When utilized, the crosslinking agent is present in an amount of greater than 0 to about 5, more typically about 0.25 to about 3 parts by weight, based on 100 parts by weight of total polyol present in the isocyanate-reactive component. Can be present in the isocyanate-reactive component.

The catalyst component of the additive component can be used to produce the elastomeric polyurethane foam in the present disclosure. Exemplary catalysts include, but are not limited to, N,N-dimethylethanolamine (DMEA), N,N-dimethylcyclohexylamine (DMCHA), bis(N,N-dimethylaminoethyl)ether (BDMAFE), N,N,N',N',N''-pentamethyldiethylenetriamine (PDMAFE), 1,4-diazadicyclo[2,2,2]octane (DABCO), 2-(2-dimethylaminoethoxy)-ethanol (DMAFE) ), 2-((2-dimethylaminoethoxy)-ethylmethyl-amino)ethanol, 1-(bis(3-dimethylamino)-propyl)amino-2-propanol, N,N',N''-tris(3 -dimethylamino-propyl)hexahydrotriazine, dimorpholinodiethyl ether (DMDEE), N. N-dimethylbenzylamine, N,N,N',N'',N''-pentaamethyldipropylenetriamine, N,N'-diethylpiperazine, and the like. In particular, sterically hindered primary, secondary, or tertiary amines are used, including, but not limited to, dicyclohexylmethylamine, ethyldiisopropylamine, dimethylcyclohexylamine, dimethylisopropylamine, methylisopropylbenzylamine, methyl Cyclopentylbenzylamine, isopropyl-sec-butyl-trifluoroethylamine, diethyl-(o-phenythyl)amine, tri-n-propylamine, dicyclohexylamine, t-butylisopropylamine, -t-butylamine, cyclohexyl-t-butylamine, de-sec-butylamine, dicyclopentylamine, di-(a-trifluoromethylethyl)amine, di-(α-phenylethyl)amine, triphenylmethylamine, and 1 , 1,-diethyl-n-propylamine may be mentioned. Other sterically hindered amines are ether-containing compounds such as morpholine, imidazole, dimorpholino diethyl ether, N-ethylmorpholine, N-methylmorpholine, bis(dimethylaminoethyl)ether, imidizole. , n-methylimidazole, 1,2-dimethylimidazole, dimorpholinodimethyl ether, N,N,N ^{, ,} N',N",N"-pentamethyldiethylenetriamine, N,N,N',N',N", N''-pentamethyldipropylene triamine, bis(diethylaminoethyl) ether, bis(dimethylaminopropyl) ether, or a combination thereof. Non-amine catalysts include, but are not limited to, stannous octoate, dibutyltin dilaurate, dibutyltin mercaptide, phenylmercuric propionate, lead octoate, potassium acetate/potassium octoate, quaternary ammonium formate, acetylacetone. Ferric acids, and mixtures thereof. The level of catalyst used is in an amount of about 0.05 to about 4.00%, about 0.15 to about 3.60%, or about 0.40 to about 2.60% by weight of the isocyanate-reactive component. could be. In certain embodiments, a catalyst component can be present in the isocyanate-reactive component to catalyze the elastomeric polyurethane forming reaction between the isocyanate component and the isocyanate-reactive component. It is to be understood that the catalyst component is typically not consumed to form the reaction product between the isocyanate component and the isocyanate-reactive component, but may contain active hydrogen groups that can react with the isocyanate group. . That is, the catalyst component typically participates in the elastomeric polyurethane forming reaction but is not consumed thereby. The catalyst component may include any suitable catalyst or mixture of catalysts known in the art. Suitable catalyst components for purposes of this disclosure are Dabco® 8154 and Dabco® 1027, commercially available from Evonik Industries (Parsippany, New Jersey).

The additive component controls the cell structure of the elastomeric polyurethane foam, affects the surface structure of the elastomeric polyurethane foam, and improves the miscibility of the components in the isocyanate-reactive component and the stability of the resulting elastomeric polyurethane foam. It may further include a surfactant that can be used for. Suitable surfactants include any surfactants known in the art, such as silicones and nonylphenol ethoxylates. In one embodiment, the surfactant can be a polysilicone polymer. In certain embodiments, the polysilicone polymer is a polydimethylsiloxane-polyoxyalkylene block copolymer. The surfactant, if present in the isocyanate-reactive component, can be selected depending on the requirements of the isocyanate-reactive component. When utilized, the surfactant may contain about 0 to about 6, about 0 to about 5, about 0.5 to about 6, or even about 0 to about 6, based on 100 parts by weight of total polyol present in the isocyanate-reactive component. It can be present in the isocyanate-reactive component in an amount of about 0.5 to 5 parts by weight. A specific example of a surfactant for purposes of this disclosure is Dabco® DC5000, commercially available from Evonik Industries (Parsippany, New Jersey).

The additive component may further include a blocking agent. Blocking agents can be used to slow cream time and increase cure time of elastomeric polyurethane foams. Suitable blocking agents include any blocking agent known in the art. In certain embodiments, the blocking agent can be an organic acid such as, but not limited to, 2-ethylhexanoic acid. Those skilled in the art typically select blocking agents depending on the reactivity of the isocyanate component, and these blocking agents are typically introduced as an integral part of the selected catalyst.

The isocyanate component and the isocyanate-reactive component can be reacted in the presence of a blowing agent to produce an elastomeric polyurethane foam. As is known in the art, during the elastomeric polyurethane forming reaction between the isocyanate component and the isocyanate-reactive component, the blowing agent promotes the release of gas that forms cellular voids in the elastomeric polyurethane foam. The blowing agent can be a physical blowing agent, a chemical blowing agent, or a combination thereof.

The term physical blowing agent refers to a blowing agent that does not chemically react with the isocyanate component and/or isocyanate-reactive component to provide a blowing gas. A physical blowing agent may be a gas or a liquid. A liquid physical blowing agent typically evaporates to a gas upon heating and evaporates from the resulting elastomeric polyurethane foam as the foam cells open. Suitable physical blowing agents for purposes of this disclosure may include liquid carbon dioxide (CO ₂ ), HCFCs, HFOs, pentane and all its isomers, acetone, entrained air, other inert gases, or combinations thereof. Most typical physical blowing agents typically have zero ozone depletion potential, such as, but not limited to, trans-1-chloro-3,3,3-trifluoropropylene (HCFO-1233zd(E)).

The term chemical blowing agent refers to a blowing agent that chemically reacts with the isocyanate component or other components to release foaming gas. Examples of suitable chemical blowing agents for purposes of the subject disclosure include, but are not limited to, formic acid, methyl formate, water, and combinations thereof. The blowing agent is typically present in the isocyanate-reactive component in an amount of about 0.5 to about 20 parts by weight, based on 100 parts by weight of total polyol present in the isocyanate-reactive component.

It should also be understood that combinations of physical and chemical blowing agents can be used. Such combinations may include, but are not limited to, water and entrained air.

The isocyanate-reactive component can also include a chain extender. Useful active hydrogen-containing chain extenders generally contain at least two active hydrogen groups, such as diols, dithiols, diamines, or hydroxyl groups, thiol groups, such as alkanolamines, aminoalkylmercaptans, and hydroxyalkylmercaptans, among others. Contains compounds with a mixture of amine groups. The molecular weight of the chain extender preferably ranges from about 60 to about 400. The chain extender, which is a structural unit that constructs the polyurethane resin, is preferably at least one selected from low molecular weight diols and low molecular weight diamines. Chain extenders can be substances that have both hydroxyl and amino groups in the molecule, such as ethanolamine, propanolamine, butanolamine, and combinations thereof.

Non-limiting examples of suitable diols that can be used as extenders include ethylene glycol and higher oligomers of ethylene glycol, including diethylene glycol, triethylene glycol, and tetraethylene glycol; propylene glycol, and dipropylene glycol; Higher oligomers of propylene glycol including tripropylene glycol and tetrapropylene glycol; cyclohexanedimethanol, 1,6-hexanediol, 2-ethyl-1,6-hexanediol, 1,4-butanediol, 2,3-butane dihydroxyalkylated aromatic compounds such as bis(2-hydroxyethyl) ethers of diols, 1,5-pentanediol, 1,3-propanediol, butylene glycol, neopentyl glycol, hydroquinone and resorcinol; p-xylene-α, α'-diol; bis(2-hydroxyethyl) ether of p-xylene-α,α'-diol; m-xylene-α,α'-diol, and combinations thereof. In certain embodiments, the chain extender is 1,4-butanediol (BDO).

Non-limiting examples of organic compounds containing at least two aromatic amine groups can be used as aromatic diamine chain extenders having molecular weights from 100 to 1,000. Amine chain extenders contain exclusively aromatically bonded primary or secondary (preferably primary) amino groups and may preferably also contain substituents. Examples of such diamines include 1,4-diaminobenzene; 2,4- and/or 2,6-diaminotoluene; 2,4'- and/or 4,4'-diaminodiphenylmethane; 3,3 '-dimethyl-4,4'-diaminodiphenylmethane; 3,3'-dichloro-4,4'-diaminodiphenylmethane (MOCA); 3,5-dimethylthiotoluene-2,4- and/or -2,6- Diamine; 1,3,5-triethyl-2,4-diaminobenzene; 1,3,5-triisopropyl-2,4-diaminobenzene; 1-methyl-3,5-diethyl-2,4- and/or -2,6-diaminobenzene (also known as 3,5-diethyltoluene-2,4- and/or -2,6-diamine, or DETDA); 4,6-dimethyl-2-ethyl-1 ,3-diaminobenzene; 3,5,3',5'-tetraethyl-4,4-diaminodiphenylmethane; 3,5,3',5'-tetraisopropyl-4,4'-diaminodiphenylmethane; 3,5- Diethyl-3',5'-diisopropyl-4,4'-diaminodiphenylmethane; 2,4,6-triethyl-m-phenylenediamine (TEMPDA); 3,5-diisopropyl-2,4-diaminotoluene; 3,5 -di-sec-butyl-2,6-diaminotoluene; 3-ethyl-5-isopropyl-2,4-diaminotoluene; 4,6-diisopropyl-m-phenylenediamine; 4,6-di-tert-butyl- m-phenylenediamine; 4,6-diethyl-m-phenylenediamine; 3-isopropyl-2,6-diaminotoluene; 5-isopropyl-2,4-diaminotoluene; 4-isopropyl-6-methyl-m-phenylenediamine ;4-isopropyl-6-tert-butyl-m-phenylenediamine;4-ethyl-6-isopropyl-m-phenylenediamine;4-methyl-6-tert-butyl-m-phenylenediamine;4,6-di- sec-butyl-m-phenylenediamine; 4-ethyl-6-tertbutyl-m-phenylenediamine; 4-ethyl-6-sec-butyl-m-phenylenediamine; 4-ethyl-6-isobutyl-m-phenylenediamine ;4-isopropyl-6-isobutyl-m-phenylenediamine;4-isopropyl-6-sec-butyl-m-phenylenediamine;4-tert-butyl-6-isobutyl-m-phenylenediamine;4-cyclopentyl-6- Ethyl-m-phenylenediamine; 4-cyclohexyl-6-isopropyl-m-phenylenediamine; 4,6-dicyclopentyl-m-phenylenediamine; 2,2',6,6'-tetraethyl-4,4'-methylene Bisaniline; 2,2',6,6'-tetraisopropyl-4,4'-methylenebisaniline (methylenebisdiisopropylaniline); 2,2',6,6'-tetra-sec-butyl-4,4 '-Methylenebisaniline; 2,2'-dimethyl-6,6'-di-tert-butyl-4,4'-methylenebisaniline; 2,2'-di-tert-butyl-4,4'-methylene bisaniline; and 2-isopropyl-2',6'-diethyl-4,4'-methylenebisaniline. Such diamines can of course also be used as mixtures.

The isocyanate component and isocyanate-reactive component typically react with an isocyanate index of about 90 or higher, more typically about 100 or higher. The term isocyanate index is defined as the ratio of NCO groups in the isocyanate component to isocyanate-reactive groups in the isocyanate-reactive component multiplied by 100. The elastomeric polyurethane foams of the present disclosure can be produced by mixing the isocyanate component and the isocyanate-reactive component to form a mixture at room temperature or a slightly elevated temperature, such as 15-45°C. It should be appreciated that in certain embodiments where the elastomeric polyurethane foam is produced in a mold, the isocyanate component and the isocyanate-reactive component can be mixed to form a mixture prior to placing the mixture in the mold. For example, the mixture can be poured into an open mold, or the mixture can be poured into a closed mold. In these embodiments, once the elastomeric polyurethane foaming reaction is complete, the elastomeric polyurethane foam assumes the shape of the mold. Elastomeric polyurethane foams can be produced, for example, in low pressure molding machines, low pressure slabstock conveyor systems, high pressure molding machines including multi-component machines, high pressure slabstock conveyor systems, and/or by hand mixing. In such embodiments, the described materials may be processed and shaped, for example, at temperatures from about 20 to about 70 degrees Celsius, or from about 20 degrees Celsius to about 60 degrees Celsius.

In certain embodiments, elastomeric polyurethane foam can be produced or placed in a slabstock conveyor system that can form elastomeric polyurethane foam having an elongated rectangular or circular shape. As is known in the art, slabstock conveyor systems contain mechanical mixing heads for mixing the individual components, e.g., isocyanate components and isocyanate-reactive components, and elastomer polyurethane forming reactions. trough, a moving conveyor for raising and curing the elastomeric polyurethane foam, and a fall plate unit for directing the expanding elastomeric polyurethane foam onto the moving conveyor.

Without intending to be bound by the following theory, the formulations in the present disclosure exhibit improved hot compression set performance and maintained exceptional tensile strength, tear strength, elongation at break, and other bring about physical properties. Without wishing to be bound by any particular theory, the resulting elastomeric polyurethane foam has a polyurethane foam of about 2 to about 3, about 2.1 to about 2.9, about 2.2 to about 2.8 , having a crosslink density of about 2.3 to about 2.6 and is therefore considered to have improved quality. The average molecular weight between each crosslinking point is about 100 to about 1000 g/mol, about 200 to about 900 g/mol, about 250 to about 650 g/mol, and the polymer assembly controls the crystallinity of the resulting polymer matrix. is designed to. Control of this crystallinity is most often established through the selection of the isocyanate-reactive component and the polyol component within the isocyanate component.

The density of the elastomeric foams of the present disclosure is between 4 and 40 pounds per cubic foot and can be determined according to ASTM D792, Method A, at about 25°C and 50% relative humidity (RH).

The elastomeric foams of the present disclosure are also evaluated for compression set and compression force deflection (CFD) according to ASTM D3574, respectively. Compression set is a measure of the permanent partial loss of a foam's original height after compression due to bending or collapse of the cell structure within the foam. Compression set is measured by compressing the foam to 90%, or 10% of its original thickness, and holding the foam under such compression at 70-150° C. for 22 to about 100 hours. Compression set is expressed as a percentage of the original compression. Finally, CFD is a measure of a foam's load-bearing performance and is measured by compressing the foam with a flat compression leg that is larger than the sample. CFD is the amount of force exerted by a flat compression leg, typically expressed as 25%, 40%, 50%, and/or 65% compression of the foam.

Samples are tested for tensile strength and elongation according to ASTM D3574. Tensile strength and elongation properties describe a foam's ability to withstand handling during manufacturing or assembly operations. Specifically, tensile strength is the force in pounds per cubic inch required to stretch the foam to its breaking point. Elongation is a measure of the percentage that the foam stretches from its original length before breaking.

Samples are tested for tear strength according to ASTM D3574. Tear strength is a measure of the force required to sustain a tear in an elastomeric polyurethane foam after tension or rupture has been initiated and is expressed in pounds per inch (ppi).

The Shore A hardness test measures the hardness of a sample according to ASTM D2240. This test is based on the penetration of a specific type of indenter when pressed into a material under specified conditions. Indentation hardness is inversely proportional to penetration and depends on the elastic modulus and viscoelastic behavior of the foam sample.

Reference is now made to specific examples illustrating the present disclosure. It is to be understood that the examples are provided to illustrate exemplary embodiments and are not intended to be a limitation on the scope of the disclosure.

Example 1
Polyol Blend Example Fill a clean container with the polyol ingredients. Begin stirring and continue throughout the batch procedure. Add all remaining ingredients except water sequentially. Blend the ingredients in the container for at least 30 minutes. A sample of the blend is taken and tested for water content via Karl Fischer titration. Add the calculated amount of water to the container to achieve the desired water level. The blend is then stirred for a minimum of 30 minutes. Polyol blend Examples 1-14 are made based on this protocol, as shown in Tables 1 and 2 below. Table 1 shows Group A for polyol blend Examples 1-8. Table 2 shows Group B, which covers polyol blend Examples 9-14. Group B does not contain polyol D (Pluracol® 2097 polyol) or polyol E (Pluracol® 4156 polyol).

Polyol A is Pluracol® 1062 polyol, which is a nominal diol capped with propylene oxide or ethylene oxide having a number average molecular weight of about 1000 g/mol to about 9000 g/mol, and polyol B is Pluracol® 1062 polyol 593 polyol, which is a nominal triol with a high proportion of randomly dispersed ethoxy groups having a number average molecular weight of about 1000 g/mol to about 8000 g/mol; Trademark) 2010/1, which is a nominal ethylene oxide-capped tetraol with a number average molecular weight of about 250 g/mol to about 6000 g/mol, and polyol D is Pluracol® 2097 polyol. , which is a nominal triol capped with ethylene oxide with a number average molecular weight of about 1000 g/mol to about 13000 g/mol, and polyol E is a Pluracol® 4156 polyol with a number average molecular weight of about 5000 g/mol. and polyol E* is Pluracol® 4156 polyol with a number average molecular weight of about 12000 g/mol, which is a nominal triol capped with propylene oxide. Catalyst A is Dabco® 8154, a blocked tertiary amine, and Catalyst B is Dabco® 1027, a delayed activation tertiary amine diluted in ethylene glycol. The surfactant is Dabco® DC5000, a non-hydrolyzable silicone glycol copolymer. The chain extender is BDO. The blowing agent is water.

When comparing the hydroxyl functionality of polyol blend samples, the chain extender BDO is excluded from the equation. In general, group A shows higher functionality compared to group B due to the higher proportion of polyol C (Lupranol® 2010/1), which is a tetrol. The higher the hydroxyl functionality, the higher the crosslinking density, which can contribute to improved high temperature performance.

Example 2
Example of Isocyanate Functional Urethane Prepolymer PMDI (Lupranate® M20) is added into a clean reaction vessel. Agitation is started and continued throughout the operation. The reaction vessel is heated to about 57 to about 63°C. Molten MMDI (Lupranate® M) is then added to the vessel. Polyol is then added at a constant rate over about 30 minutes and the temperature of the reaction mixture is monitored and controlled not to exceed about 80°C. The reaction is allowed to proceed at about 77 to about 83°C for about 1 hour, then cooled to about 25 to about 40°C and sampled for final analysis. Upon quality control approval, the prepolymer product is transferred to a shipping container using a 50 micron filter. Prepolymer Examples 1-4 are made according to the above protocol, as shown in Table 3 below.

When using higher proportions of PMDI (Lupranate® M20), the prepolymer exhibits higher isocyanate functionality. Prepolymer samples 1-3 use the same polyol (Pluracol® 410), which is essentially propylene glycol. MMDI (Lupranate® M) is gradually increased to investigate the effect on foam properties. Prepolymer Sample 4 uses Polyol A (Pluracol® 1062), the same polyol used to prepare the foam samples.

Example 3
Foam Examples Set the drill press at a speed of 2340-3100 rpm and mix timer for 10-25 seconds. A mold release agent is applied to an aluminum block mold heated to about 35-60°C. Typical sizes for test block molds are 12 inches x 12 inches x 0.5 inches (30.5 cm x 30.5 cm x 1.3 cm) or 12 inches x 12 inches x 0.25 inches (30.5 cm x 30.5 cm). x0.6cm). Weigh a predetermined amount of isocyanate-reactive component (resin) into a mixing cup and a predetermined amount of isocyanate component (ISO) into a second mixing cup. Pour the prepolymer into the cup containing the resin. The mixing blade is then submerged into the mixing cup and the mixer is started. After mixing for a set time, pour the reaction foam from the mixing cup into the mold and close the mold. After about 4 to about 7 minutes, open the mold and remove the foam block. As shown in Tables 4 and 5 below, elastomeric polyurethane foam Examples 1-17 are made based on the above protocol. Foams made with only Pluracol® 1062 polyol or Pluracol® 593 polyol have very poor properties and in some cases may not be stable enough for the foam to rise. be.

As shown in Tables 4 and 5, the elastomeric polyurethane foams of the present disclosure have constant deflection compression set values at 40% deflection of less than about 40% even when the foam samples are compressed under severe conditions such as at 100°C to 130°C for 96 hours. The elastomeric polyurethane foams of the present disclosure have tensile strength values of about 50 lbf/in2 to about 285 lbf/in2. The tear strength values are about 13 lbf/in2 to about 40 lbf/in2. The elongation at break values are about 50% to about 160%.

Two different aging conditions are used to determine the foam properties: 70 hours exposure at 102°C and 168 hours exposure at 60°C and 95% relative humidity. Tensile strength, elongation, tear strength, and Shore A hardness are tested before and after aging. When aged at 102°C for 70 hours, the tensile strength values of the elastomeric polyurethane foams of the present disclosure undergo a change of less than about 50%, the tear strength values undergo a change of less than about 30%, and the elongation at break values: undergoes a change of less than about 50%. When aged for 168 hours at 60° C. and 95% relative humidity, the tensile strength values of the elastomeric polyurethane foams of the present disclosure undergo a change of less than about 35%, and the tear strength values undergo a change of less than about 35% before breaking. Point elongation values undergo a change of less than about 35%. The small property changes at different aging conditions confirm the improved high temperature performance of the elastomeric polyurethane foams disclosed herein.

Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific compositions and procedures described herein. Such equivalents are considered to be within the scope of this disclosure and are covered by the following claims.

Claims (39)

An elastomeric polyurethane foam having improved hot compression set values, the foam comprising:
(a) one or more prepolymers comprising monomeric diphenylmethane diisocyanate (MMDI) or polymeric MDI (PMDI) and isocyanate-functional urethane prepolymers derived from polyether diols;
(b) an isocyanate-reactive component,
(i) a first polyol in an amount of from 10 to 70 parts by weight of said isocyanate-reactive component, wherein said first polyol is propylene oxide or ethylene oxide having a number average molecular weight of from 1000 g/mol to 9000 g/mol; a first polyol that is a nominally capped diol;
(ii) a second polyol in an amount of 0 to 50 parts by weight of said isocyanate-reactive component, wherein said second polyol is a randomly dispersed polymer having a number average molecular weight of 1000 g/mol to 8000 g/mol; a second polyol, which is a nominal triol having a proportion of ethoxy groups;
(iii) a third polyol in an amount of 0 to 20 parts by weight of said isocyanate-reactive component, said third polyol capped with ethylene oxide having a number average molecular weight of 250 g/mol to 6000 g/mol. a third polyol, nominally a tetraol, and (iv) a fourth polyol in an amount of from 0 to 80 parts by weight of said isocyanate-reactive component, wherein said fourth polyol is from 1000 g/mol to 13000 g/mole. a fourth polyol, which is a nominal triol capped with ethylene oxide or propylene oxide, having a number average molecular weight of molar;
the second polyol comprises 15 to 40 parts by weight of the isocyanate-reactive component;
An elastomeric polyurethane foam comprising the reaction product of a component comprising an isocyanate-reactive component, wherein components (ii), (iii), and (iv) are present in greater than 0 parts by weight. The elastomeric polyurethane foam of claim 1, wherein the first polyol comprises 30 to 70 parts by weight of the isocyanate-reactive component. The elastomeric polyurethane foam of claim 1, wherein the first polyol comprises 35 to 65 parts by weight of the isocyanate-reactive component. The elastomeric polyurethane foam of claim 1, wherein the third polyol is in an amount of 0 to 15 parts by weight of the isocyanate-reactive component. The elastomeric polyurethane foam of claim 1, wherein the third polyol is in an amount of 0 to 10 parts by weight of the isocyanate-reactive component. The elastomeric polyurethane foam of claim 1, wherein the fourth polyol is in an amount of 0 to 30 parts by weight of the isocyanate-reactive component. The elastomeric polyurethane foam of claim 1, wherein the fourth polyol is in an amount of 0 to 15 parts by weight of the isocyanate-reactive component. Elastomeric polyurethane foam according to claim 1, wherein the first polyol has a number average molecular weight of 6000 g/mol and a functionality of 1.5 to 2.0. The elastomeric polyurethane foam of claim 1, wherein the second polyol has a number average molecular weight of 3600 g/mol and a functionality of 2.8 to 3.0. The elastomeric polyurethane foam of claim 1, wherein the third polyol has a number average molecular weight of 5250 g/mol and a functionality of 3.5 to 5.0. Elastomeric polyurethane foam according to claim 1, wherein the fourth polyol has a number average molecular weight of 2800 to 6000 g/mol and a functionality of 2.1 to 3.0. The isocyanate-reactive component further includes an additive package in an amount of 1 to 30 parts by weight of the isocyanate-reactive component, and the additive package includes blowing agents, catalysts, colorants, dyes, pigments, crosslinkers, Ingredients selected from fuels, diluents, solvents, inorganic fillers , antioxidants, UV stabilizers, biocides, adhesion promoters, antistatic agents, mold release agents, fragrances, and any combinations thereof. The elastomeric polyurethane foam of claim 1, comprising: The elastomeric polyurethane foam of claim 1, wherein the isocyanate-reactive component further comprises a surfactant in an amount of 0 to 5 parts by weight of the isocyanate-reactive component. 14. The elastomeric polyurethane foam of claim 13 , wherein the surfactant is a non-hydrolyzable silicone glycol copolymer. The elastomeric polyurethane foam of claim 1, wherein the isocyanate-reactive component further comprises a chain extender in an amount of 0 to 10 parts by weight of the isocyanate-reactive component. The elastomeric polyurethane foam of claim 15, wherein the chain extender is 1,4-butanediol. The elastomeric polyurethane foam of claim 1, wherein the isocyanate-reactive component further comprises a chemical blowing agent in an amount of 0.1 to 4 parts by weight of the isocyanate-reactive component. The elastomeric polyurethane foam of claim 17, wherein the chemical blowing agent is water. The elastomeric polyurethane foam of claim 1, wherein the isocyanate-reactive component further comprises a physical blowing agent in an amount of 0 to 12 parts by weight of the isocyanate-reactive component. The elastomeric polyurethane foam of claim 19, wherein the physical blowing agent is HCFO-1233zd(E). The elastomeric polyurethane foam of claim 1, wherein the MMDI is in an amount of 20 to 70 parts in the isocyanate-functional urethane prepolymer . The elastomeric polyurethane foam of claim 1 , wherein in the isocyanate-functional urethane prepolymer, the PMDI is in an amount of 20 to 70 parts. The elastomeric polyurethane foam of claim 1, wherein the polyether diol is in an amount of 5 to 30 parts in the isocyanate-functional urethane prepolymer . The elastomeric polyurethane foam of claim 1, wherein the MMDI is at least 97% by weight 4,4'-MDI. The elastomeric polyurethane foam of claim 1, wherein the PMDI has a viscosity of 150 to 850 cps at 25°C and a percent NCO of 30 to 32.5. The elastomeric polyurethane foam of claim 1, wherein the polyether diol has a number average molecular weight of 425 g/mole and a functionality of 1.75 to 2.0, or a number average molecular weight of 6000 g/mole and a functionality of 1.5 to 2.0. The elastomer of claim 1, wherein the compression set value of the foam at 30% to 50% deflection according to ASTM D3574 is less than 40% when the foam sample is compressed for 22 to 100 hours at 70°C to 150°C. Polyurethane foam. Claim 1, wherein the constant deflection compression set value of the foam at 30% to 50% deflection according to ASTM D3574 is less than 40% when the foam sample is compressed for 22 to 100 hours at 100°C to 130°C. Elastomeric polyurethane foam as described. The tensile strength values of the foam according to ASTM D3574 range from 50 x 50 lbs./(25.4 mm) ² (square inches) to 285 x 285 lbs./(25.4 mm) ² (in square inches). Claiming that the tear strength value of the foam according to ASTM D3574 is from 13 x 0.4536 kg (13 lbs. force)/25.4 mm (in.) to 40 x 0.4536 kg (40 x 0.4536 kg (40 lbs.)/25.4 mm (in.) Elastomeric polyurethane foam according to item 1. The elastomeric polyurethane foam of claim 1, wherein the elongation at break value of the foam according to ASTM D3574 is between 50% and 160%. The elastomeric polyurethane foam of claim 1, wherein the tensile strength value of the foam according to ASTM D3574 undergoes less than a 50% change when the foam is aged at 102°C for 70 hours. The elastomeric polyurethane foam of claim 1, wherein the tear strength value of the foam according to ASTM D3574 changes by less than 30% when the foam is aged at 102°C for 70 hours. The elastomeric polyurethane foam of claim 1, wherein the elongation at break value of the foam according to ASTM D3574 undergoes less than a 50% change when the foam is aged at 102°C for 70 hours. 2. The elastomeric polyurethane foam of claim 1, wherein the tensile strength value of the foam according to ASTM D3574 undergoes less than a 35% change when the foam is aged for 168 hours at 60<0>C and 95% relative humidity. The elastomeric polyurethane foam of claim 1, wherein the tear strength value of the foam according to ASTM D3574 changes by less than 35% when the foam is aged for 168 hours at 60°C and 95% relative humidity. 2. The elastomeric polyurethane foam of claim 1, wherein the elongation at break value of the foam according to ASTM D3574 undergoes a change of less than 35% when the foam is aged for 168 hours at 60<0>C and 95% relative humidity. 1. A method of forming an elastomeric polyurethane foam, the method comprising:
(a) reacting a prepolymer with a polyether diol to form an isocyanate-functional urethane prepolymer, said prepolymer comprising MMDI and/or PMDI;
(b) blending at least a first polyol, a second polyol, a third polyol, and a fourth polyol to form an isocyanate-reactive component;
(c) mixing the isocyanate- functional urethane prepolymer and an isocyanate-reactive component at an isocyanate index of 100 to 110 to form an elastomeric polyurethane foam;
the first polyol is a nominal diol capped with propylene oxide or ethylene oxide having a number average molecular weight of 1000 g/mol to 9000 g/mol, comprising 10 to 70 parts by weight of the isocyanate-reactive component;
the second polyol is a nominal triol having a high proportion of randomly dispersed ethoxy with a number average molecular weight of 1000 g/mol to 8000 g/mol and containing 0 to 50 parts by weight of the isocyanate-reactive component;
said third polyol is a nominal ethylene oxide-capped tetraol having a number average molecular weight of 250 g/mol to 6000 g/mol and comprises 0 to 15 parts by weight of said isocyanate-reactive component;
said fourth polyol is a nominal triol capped with ethylene oxide or propylene oxide having a number average molecular weight of 1000 g/mol and 13000 g/mol and comprises from 0 to 80 parts by weight of said isocyanate-reactive component;
the second polyol comprises 15 to 40 parts by weight of the isocyanate-reactive component;
the second polyol, the third polyol and the fourth polyol are present in an amount greater than 0 parts by weight;
Method. 39. The method of claim 38, further comprising blending an additive package with 1 to 30 parts by weight of said isocyanate-reactive component, said additive package comprising components selected from blowing agents, catalysts, colorants, inorganic fillers, antioxidants, and any combination thereof .